Prefab Utility Wall

ABSTRACT

The wall is comprised of a shower base or bathtub, toilet, sink, water heater, lighting, washing machine and dryer hook-up, as well as a complete electric service including a breaker box, electric outlets and light fixtures. The wall also contains pipes for a sink drain and for hot/cold water for an attached kitchen. The utility wall requires no underground plumbing.

DESCRIPTION OF PRIOR ART

Most residential and commercial buildings are built on concrete slabfoundations. Some residential buildings are still constructed onconcrete piers, and in coastal areas, they are often built on woodenpiers, but seldom concrete piers.

Buildings on concrete slab foundations require underground plumbing. Theplumbing is placed after the channels for the grade beams are dug andthe forms are set in place. After that procedure, the entire area of theslab, including the grade beam channels, are covered with thick plasticsheeting. The next step involves carefully installing the undergroundPVC plumbing pipes. After installation, the pipes have to be sealed andplugged as they will be tested for leaks by filling them with water. Thefinal step of the slab preparation process involves the installation ofthe steel reinforcing bars required for the foundation. Before theconcrete can be poured for the foundation, the governing agency, usuallythe City or County, will inspect the plumbing work, the reinforcingsteel, the final measurements for the correct location of the concreteslab and perform the leak test.

Building on piers is an easier task, as there is no undergroundplumbing. The installation of plumbing can be done at a later time.However, all of the before-mentioned steps of preparing the work beforethe concrete can be brought in and even the pouring of the concrete forthe slab foundation is dependent on favorable weather conditions.

When an unsuspected rain shower or sudden downpour occurs during theplacing of the concrete, it can cause serious problems, as rain watercan destroy the concrete work. Concrete washes out, which means that atleast some of the cement from the concrete mixture will run out with therain water, depending on the amount of rainfall. As the cement is thebinder between the sand and gravel, the integrity, and therefore thedesired strength of the concrete, is negatively impacted. This can thenturn into an expensive repair job, and sometimes the concrete mixturehas to be replaced. To prevent rain from negatively impacting a concreteinstallation, work has to sometimes be performed at night with speciallighting and special delivery ready mix concrete. Moreover, during rainyperiods, concrete trucks cannot drive on the rain-softened ground closeto a foundation site in order to prevent from getting stuck in the mud,resulting in the foundation contractor or builder to have to bring in aconcrete pump, adding to the expense of building the foundation. Thereare many other problems when a concrete job goes bad. Water has to bepumped out, forms may need to be replaced, steel reinforcing bars haveto be re-set, and the plastic sheeting may have to be repaired, adjustedor replaced.

This is part of the construction business. If the entire concrete slabis not poured at the same time, money will surely be lost in theoperation. During the construction of the building slab, it is much moreunlikely that problems will arise if underground plumbing is notnecessary.

Some claims of solutions to this problem have previously been published:

-   1. Alexander Barrenburg, U.S. Pat. Nos. 4,919,164 and 5,076,310    presented a plumbing wall which does require underground plumbing.    The plumbing wall is unfinished and consists of an open wall without    installed fixtures.-   2. McLuskey, Patent Application # US 2010/0126082 A1 presents    various ideas in different assemblies. There is no mention of    above-floor drain pipes.-   3. L. Barrett, Patent Application # US 2009/0100769 A1 presents a    heavy steel structure with labor-intensive assembly work which    requires specially trained workers to assemble the wall. Again,    there are no above-floor drain pipes.-   4. N. Herzog, Patent Application # US 2003/0140572 A1 is a design    which requires extensive assembly work and well-trained workers to    assemble the plumbing wall. The invention does not contain    above-floor drain pipes.-   5. A European system (see enclosed picture) was studied which    consists of a labor-intensive system and which requires a pony wall.    This system also needs separately designed assembly wall sections    for the toilet, sink, bath tub, and the shower base. It can have    above-floor or under-floor drainage pipes. This system is designed    for buildings without wood or steel frame work, so it is proposed    for solid stone or brick walls.

The before-mentioned five solutions/inventions are not applicable forlow-cost housing, apartment buildings, motels/hotels, etc. The buildingindustry has not adjusted to these designs, as they were proposedbetween 2003 and 2010, and we found no instances of them being usedsuccessfully in any applications. These inventions are more expensiveand most of them require specialized assembly on site.

The plumbing pipe installation process in the building industry hasremained virtually unchanged over the past few decades. Only some of thematerial has changed, i.e. stronger, more temperature-resistant PVCpipes, for instance. Plumbing pipes still have to be cut, assembled andadjusted on the job site. Cupplings and elbows still must be joined andglued together on-site and holes/pipe openings must be cut in floors,ceilings, and wall frames. Before the walls are closed/finished, thepipes need to be tested for leaks, and the builder must schedule andwait for an inspector to come and inspect the plumbing installation.

A pre-fabricated plumbing wall is faster to install and it can beinstalled by mostly unskilled workers. It is less expensive to installcompared to other options. It can be handled and transported similar topre-fabricated trusses, pre-fabricated joists, pre-fabricated windowsand doors, and the toilet outlet is always 12 inches from the wall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The above general description of the method and the following detaileddescription are merely illustrative of the subject invention and modes,advantages and particulars of this invention (can) be readily suggestedto those skilled in the art without departing from the spirit and scopeof the invention.

In accordance with the present invention, the Prefab Utility WallSystem, FIG. 1, consists of a partial enclosure of 7 feet 6 inches by 3feet made of either a wood or steel frame. FIG. 2, which is covered onthree vertical sides 10, 11, 12; FIG. 3 and the floor, FIG. 3-8, coveredwith structural plywood or equivalent material. The floor frame isdesigned so as to provide a space for the drain and water pipes and, ifrequested, also gas lines. The back wall, 10, or plumbing wall in FIG. 3also comprises the electric service and wire connections for the waterheater as well as the electric outlets for water heater and clotheswasher/dryer. The drain pipes for the shower base or bathtub and toiletare underneath the subfloor FIGS. 1-3, “7”. Therefore there is nounderground piping necessary for the exterior pipe connection.

The utility wall has been designed so as to fit inside a standard 8 footshipping container, FIGS. 5 and 7 or on a truck bed which is 8 footwide. All electricals, plumbing, and appliance components are designedin accordance to the International Residential Code (IRC).

After connecting the water supply and electric power all appliances willbe immediately functional. Likewise after connecting the sewer pipe,FIG. 3-14 to the city sewer or septic system it will also be functional.

The utility wall can easily be connected with other walls for bathroomsof many sizes and finishes, FIG. 12.

The presented invention of the Prefab Utility Wall System, FIG. 1, hasunlimited use in various building applications, such as in homes,apartments FIG. 5, 6,7; hotels, shelters FIGS. 5-7; housing on oil rigs,low-cost housing, hospitals (multi-stories if requested, and FEMAhousing. Using the latter as an example, FEMA could convert and steel ormasonry building with water and sewer connection into an emergencyshelter rapidly and without large cost outlays.

Also on existing concrete foundation slabs that remain after a house hasbeen destroyed by tornados, hurricanes or by fire, the present inventionoffers a faster and cost-saving solution to rebuilding a destroyedbuilding. Furthermore, it would not matter if sewer drain(s) FIG. 6; 1,2, 3 are located at the perimeter of the concrete slab, FIGS. 6; 1 and2, as the Prefab Utility Wall would have a 10 to 12 inch offset from theoutside edge of the concrete slab FIG. 7-14. In case of FIG. 7-2, itwould be easy to frame around.

Due to the design of a partial subfloor, FIGS. 3-7, underneath theshower base or bathtub the toilet is raised about 4 inches off thefloor. This makes it more comfortable for tall, elderly and handicappedpersons. Although extra-high toilets are usually more costly, theyoccasionally required.

Overall, the Prefab Utility Wall System is unique in that it can beutilized with or without underground plumbing, is comprised of anelectric breaker box already wired for outlets, light fixtures, hotwater heater, washer and dryer, and other electrical appliances; and itoffers substantial cost savings in both labor and material.

DETAILED DESCRIPTION OF DRAWINGS

FIG. 1 demonstrates a three-sided enclosure, consisting of floor 8, backwall 10, right wall 11 and left wall 12. The figure shows all appliancesin place: shower base 2, toilets 3, sink 4, electric breaker box 9, andwater heater 10.

The toilet, 3 and shower base 2 mount on a 3½ inch high subfloor. Thesubfloor 7 is comprised of drain pipes, FIGS. 3, 14 and 14A. For bathtubinstallation, water connections, FIGS. 1 and 33-, 30 and 31, areprepared.

FIG. 2 shows the framework for the partial enclosure. The frame designis made from wood or steel studs and screw together. Then the outsidewall covering, 10, 11 and 12 are screwed to the frame. Structuralplywood or equivalent material should be used. The floor parts 7 and 8are made from heavy plywood. Supports of the subfloor 15, are made from2×4 studs. For a bathtub application instead of a shower base thesubfloor 7, and the exterior wall 11, will be extended by 2 feet so astandard size, 5 foot long bathtub can be set: FIG. 6, and extendeddetail 50 (interrupted lines).

FIG. 3 shows a set-up of the appliances with the drain pipes. Mostpipes, 14 and 16 are mounted in the back wall, 10. The pipes 14 and 14Aare in cavity between floor 8 and subfloor 7. The drain pipe 16A for thewashing machine and kitchen sink are inside wall 12. 15A shows thesiphon for the shower or bathtub.

FIG. 4. The drawing shows a house with an installed Prefab Utility Wallunit. On a new as well as on an existing building a 3′ 3″×8′ opening isnecessary. The backside of the utility wall has to face the exteriorwall in order to connect to a sewer drain pipe.

FIG. 5 shows the Prefab Utility Wall with a shower base used in astandard 8 foot by 20 foot shipping container. The installation of thePrefab Utility Wall can easily be performed by opening the two containerdoors on any standard shipping container.

FIG. 6 shows the Prefab Utility Wall will be installed with a standard 5foot long bathtub.

FIG. 7 demonstrates the use of the Prefab Utility Wall on an existingslab, A: for example following a tornadic or similar event has leveled astructure. In picture 1 there are three drain pipe outlets. The utilitywall can be easily set next to any drain outlet. Instead of just usingthe Prefab Utility Wall, another option is to place a standard shippingcontainer, FIG. 5 or 6, with the Prefab Utility Wall already installedinside of the container, on top of the slab.

FIG. 8 demonstrates the method of the Prefab Utility Wall with a bathtubinstead of a shower base, where 7A is the subfloor and 11A is thesidewall. If a whirlpool is favored in lieu of a bathtub, a whirlpoolpump can be connected at 9AA, electrical outlet. The water connections30, 31+

will be the same as those for the shower stall.

FIG. 9 demonstrates the integration of the Prefab Utility Wall asinstalled in a shipping container, efficiency apartment, or oilfieldhousing or other structures. The drawing depicts a three-dimensionalview of a fully-furnished, standard 20 foot long shipping container. Theutility wall will be installed in the same way as mentioned in FIGS.5+6, through the existing container doors.

FIG. 10 shows a regular building on a concrete slab foundation, A. Thebuilding—a small house—has a 3′ 3″×by 8′ opening cut-in for installationof the Prefab Utility Wall. The opening can be vertical or horizontal.

FIG. 11 demonstrates the installation of the Prefab Utility Wall in a2-story building, II. The 1^(st) floor I, is identical to the 2^(nd)floor, with 10 a cut-out showing partial view of the Prefab UtilityWall. For installation on buildings with more than 2 stories, thedrawing for the next stories would be equivalent to the first and secondstories as shown in FIG. 11.

FIG. 12 demonstrates two different bathroom layouts. Picture Iillustrates a larger bathroom than picture II. Picture I suggests 3different access door possibilities. Picture II demonstrates a low-costdesign with an attached kitchen sink 19 and 20 being the exteriorbuilding walls. Layouts for custom designs with the use of basic utilitywall is unlimited. This drawing shows only two designs.

1. Prefab Utility Wall System consists of a wall that combines plumbingand electric service, and which connects plumbing appliances withfixtures.
 2. Prefab Utility Wall System after claim 1 comprises asubfloor underneath the shower or bathtub and toilet, that does notexceed 4 inches in extra height.
 3. Prefab Utility Wall System afterclaim 1 uses the subfloor to house waste pipes for the shower base orbath tub and toilet.
 4. Prefab Utility Wall System after claim 1 has alldrain pipes above the floor.
 5. Prefab Utility Wall System after claim 1has a maximum weight of 200 pounds.
 6. Prefab Utility Wall System afterclaim 1 has two horizontal support walls each 3 feet long fortransportation purposes.
 7. Prefab Utility Wall System after claim 1 hasa round or oval drain pipe.